Mechatronic integration facilitates control system design
A new approach for control system design uses mechatronic integration. Prior to modifying the feed-drive module of a 5-axis machining center, a full simulation model was automatically generated from the construction assembly model. Preparation, modification, and testing were all in the Matlab/Simulink environment, streamlining the process.
In metalworking machine tools, a new era is beginning for the design of control algorithms to ensure high-quality work. Full integration of software tools (from project design to final implementation of control system) for machine tool controls development is inevitable.
The project involved advanced simulation research into the design and development of the family of high-performance, versatile 5-axis machining centers with X-type 5, providing unique characteristics and technological opportunities. The project was carried out by a consortium composed of machine tool Polish vendor FOP AVIA, Poznań University of Technology, and West Pomeranian University of Technology. Integration of CAD/CAM tools with the Matlab/Simulink environment provided advantages for prototyping new algorithms for control of feed drive modules.
Construction of feed drive variants
Construction assembly of a new machining center was prepared with SolidWorks software integrated development environment (IDE).
The so-called virtual modifications have been done to the feed drives of machine tools by providing synchronous linear motors within the project. Siemens 1FN series linear motors models that can be driven with Heidenhain's iTN530 CNC system were used during the new feed drives variant design for the X-5 machining center.
Design calculations and modifications were introduced into dynamic simulation models, taking into account the modification of the structure and characteristics of the cascaded servo control system (position-velocity-current) typical for the application of digital control of drives in CNC machines.
Figure 4 shows a computer simulation example. The set position in Z axis was changed as shown.
Project flow: Feed-drive module variant
Figure 5 shows the complete workflow schema on a new variant of the feed-drive unit for machine tool type X-5.
Using a mechatronic approach [considering mechanical and electrical components together in an integrated design] and automatic code generation of the Simulink/SimMechanics model from the prepared SolidWorks assembly allowed the project team to effectively compare and analyze the feed drive variants.
Software for mechatronic design
The software tools enabled the mechatronic design of new variants for the feed drive module actuators in the 5-axis machining center. Matlab/Simulink functionality helped create a set of optimization scenarios and criteria as the basis for future research.
The X-5 machining center was honored with the Gold Medal Award of the Mach-Tool International Fair in Poznań, Poland, in 2013, as one of the most innovative machining centers. While the linear motor feed drive variant is only a numerical prototype, calculations conducted within the project reliably reflect modern technological capabilities. The sky is the limit in the world of mechatronic design.
- Paweł Paśnicki is R&D director at AVIA FOP Warsaw, Poland; Krzysztof Pietrusewicz and Mirosław Pajor are with West Pomeranian University of Technology, Szczecin; and Roman Staniek is with Poznan University of Technology. They also contribute to Control Engineering Poland. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske(at)cfemedia.com.
At the bottom of this file see other linked advanced controls articles from these researchers.
At www.controleng.com/international, see other global contributions from Control Engineering.
Case Study Database
Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.
These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.
Click here to visit the Case Study Database and upload your case study.
Annual Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.